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GEA offers different types of air-cooled heat exchangers to meet customer needs. Key design considerations include the fan and tube bundle arrangement, header construction, and finned tube design. Induced draft units protect finned surfaces from weather, while forced draft units allow easy access for maintenance. Header types include plug, removable cover plate, and welded designs suitable for different pressures and fluids. Finned tubes are made from materials like aluminum and stainless steel in configurations like extruded, embedded, and galvanized elliptical designs.
GEA offers different types of air-cooled heat exchangers to meet customer needs. Key design considerations include the fan and tube bundle arrangement, header construction, and finned tube design. Induced draft units protect finned surfaces from weather, while forced draft units allow easy access for maintenance. Header types include plug, removable cover plate, and welded designs suitable for different pressures and fluids. Finned tubes are made from materials like aluminum and stainless steel in configurations like extruded, embedded, and galvanized elliptical designs.
GEA offers different types of air-cooled heat exchangers to meet customer needs. Key design considerations include the fan and tube bundle arrangement, header construction, and finned tube design. Induced draft units protect finned surfaces from weather, while forced draft units allow easy access for maintenance. Header types include plug, removable cover plate, and welded designs suitable for different pressures and fluids. Finned tubes are made from materials like aluminum and stainless steel in configurations like extruded, embedded, and galvanized elliptical designs.
GEA offers a range of different air-cooled heat exchanger
configurations in order to meet the specific requirements of both the process and the site location. Whatever the configuration, one of the most important design criteria is to ensure that air is allowed to freely enter and leave the system, ensuring maximum heat transfer.
Induced draft: The Induced draft unit gives a steady and durable thermal performance due to the protection of the finned surface against wind, rain, hail and snow by the plenum chamber. The induced draft also ensures a better air distribution, less hot air recirculation, less air- side fouling and lower noise levels at grade.
Forced draft: The forced draft unit allows an easy access for maintenance to the fans and to the bundles. Furthermore, the fans remain in the cold ambient air. HEADER CONSTRUCTION:
D-type Header: The welded bonnet type header is used in some cases for special services such as: ammonia, freon and vacuum steam condensers. One advantage of this design is the full welded construction which provides the perfect sealing required for such applications.
Induced draft fan arrangement
Forced draft fan arrangement
Forced draft unit at Mosgas
Plug Type Header: The plug header is the most commonly used up to 350 bar working pressure. The plug hole opposite each tube allows expansion of the tube in the tube sheet, mechanical cleaning, and plugging in case of leakage Seal welding or strength welding can be provided for high partial hydrogen pressure services resulting in a less expansive solution than the use of pipe header generally used for over 200 bar service pressure.
Removable Cover Plate Header: The cover plate header is used for fluids with high fouling factors up to 40 bar working pressure where a frequent mechanical cleaning is necessary. It is used also for very corrosive process fluids so as to periodically check the corrosion allowance. Special cover plate headers using welded gaskets are provided for hydrogen service units in hydrocracking plants. FAN DRIVES:
Fan blades are generally made of either aluminium or glass reinforced plastic (GRP). The number and the rotational speed of the blades depends on the air-flow and noise requirements. Different kinds of belt drive systems are used depending on the transmission power and client preferences. The different belts used are v-belts, integral v-belts and toothed high torque drive (HTD) belts. For higher powered systems (over 37 kW), gear drives (parallel shaft or right angle) are preferred. Electric motors are generally used as drivers, but steam or hydraulic turbines as well as low speed direct drive electric motors can also be used. Air-flow control can be realised using either manual or automatic variable pitch fans or variable speed electric drives (variable frequency).
FINNED TUBES GEA Aircooled Systems manufactures various types of aluminium, copper, stainless steel and galvanised carbon steel finned tubes, according to customer specifications in terms of working temperature, ambient temperatures, corrosive atmospheres, etc. . 1. EXTRUDED FIN Application: High-efficiency fins for various temperature applications, giving the base tube complete and permanent protection against atmospheric corrosion. The extruded fin is very robust and resistant to mechanical damage, allowing the fins to be easily cleaned with steam or water. Maximum Operating Temperature: 300 C Manufacture: A carefully degreased core tube is fitted into an aluminium sleeve. This assembly is then fed into the triple-spindle finning head of the fin-extruding machine. Three special multidisc packs extrude the aluminium tube i helical high fins, reducing the inner diameter of the sleev give firm pressure contact with the base tube. 2. G FIN (EMBEDDED OR GROOVED FIN) Application: High-efficiency fin for high temperature applications. Maximum Operating Temperature: 400 C Manufacture: A helical groove is formed in the base tube without removing any material and the fin is then wound into the groove under tension, followed by backfilling and knurling of the displaced material to lock the fin root into the tube. Fin Material: Aluminium/copper/stainless steel. Base Tube Material: Any readily machinable material.
3. DOUBLE L FIN (LL FIN) AND L FIN Application: Standard fin for low-temperature applications where some degree of tube wall protection is required. Maximum Operating Temperature: 120 C Manufacture: The fin foot is pre-formed into an L shape and applied to the base tube under tension. Each fin abuts an adjacent fin, giving a degree of protection to the base tube in less aggressive environments. Fin Material: Aluminium/copper. Base Tube Material: Any metallic material. 4. HOT-DIP GALVANISED ELLIPTICAL TUBES WITH RECTANGULAR FIN Application: This finned tube is optimally shaped and has excellent thermodynamic properties. The fin collar forms a permanent METALLIC bond with the tube. Corrosion resistance is excellent, thanks to hot-dip galvanising, which produces a protective, self-healing, outer-layer. The design is compact, resulting in a small heat exchanger
Collection of finned tubes
Extruded fin
G fin
L fin
nt e to o bundle face area. Maximum Operating Temperature: 350 C Manufacture : The fins are first punched out and then lined up automatically on the tube. The end fins are fixed. Integrated spacers in the fins maintain the desired gap between adjacent fins. The use of a specially developed hot-dip galvanising bath produces the best possible metallic fin-to-tube bond and results in excellent heat transfer and mechanical properties. Fin Material: Steel, galvanised. Base Tube Material: Steel, galvanised. . Hot dip galvanised rectangular fins Fin Selection Table: 1. 2. 3. 4.
Maximum Working Temperature 300 deg C 400 deg C 120 deg C 250 deg C 120 deg C 350 deg C Atmospheric Corrosion Resistance Excellent Poor Acceptable Medium Medium Excellent Mechanical Resistance Excellent Poor Acceptable Medium Medium Excellent Price Index 125 105 100 102 105 N/A
Air Fin Coolers (AFC)
Air Cooled Heat Exchangers are used to cool and / or condense various process fluids in Refinery, Petrochemical, Fertilizer Process Industries, etc. These are used where there is scarcity of water and water is costly. Air Cooled Heat Exchangers are generally arranged as tube bundles side by side or mounted one over other. The principal parts of tube bundles are headers and finned tubes.
The Air Cooled Heat Exchangers employ axial flow fans which are large volume, low pressure devices to move air uniformly across the tube bundles to cool / condense the process fluids.
The other major Auxillary components of Air Cooled Heat Exchangers are the Plenum chambers to distribute the air uniformly over the surface of tube bundle and structurals to mount the tube bundle assembly.
The Construction of the Air Fin Cooler structures are completely bolted type, to enable the user for easy erection and maintenance.
Induced Draft Unit
In induced draft-design, air is pulled across the finned tube surface and the fan is located above the tube bundle. The induced draft gives a steady and durable thermal performance due to the proctection of the finned surface chamber. The induced draft design ensures better air distribution, less hot air recirculation and low noise level at grade.
Forced Draft Unit
The forced draft unit pushes across the finned tube surface. The fans is located below the tube bundle.The forced draft unit a allows an easy access for maintenance to the fans and to the tube bundles. Also, the fans remain in the cold ambient condition.
Reference
GEA Air Cooler at Officers Club in Abu Dhabi
PLATE HEAT EXCHANGERS Depending on the application, GEA offers its clients the following diverse range of plate heat exchangers and evaporator systems: . GASKET PLATE HEAT EXCHANGERS: Varitherm: Extends to 23 different plate types for cooling and heating liquids and for condensing vapours. Free-Flow: For liquids containing a high proportion of undissolved solid matter. Concitherm: Evaporator system for sensitive products requiring short heat contact times. BRAZED PLATE HEAT EXCHANGERS: These compact units consist of profiled stainless steel plates, which are brazed together in a high vacuum furnace. Used in high pressure and/or high temperature applications, or where gaskets are prone to chemical attack.
Various plate profiles and geometries are available
Plate heat exchanger assemblies
COMPRESSOR INTER- AND AFTER-COOLERS INCLUDING OXYGEN COOLERS All types of finned tubes for air-coolers, compressor inter- and after-coolers and motor-coolers are produced at GEA's factory at Roodekop, Germiston. GEA Aircooled Systems, recognised as a leader in the heat exchanger industry in South Africa over the past 25 years, has been granted a provisional patent for the manufacturing process of copper finned tubes suitable for 100% oxygen duty. The double "L" finned tube, successfully produced after an extensive research and development programme, is in accordance with the Mannesmann Demag cleaning specification No. 010 008 99. It also complies fully with the Vecom specification SPI 2411 for oxygen compressor duty, which specifies a contamination level of hydrocarbon and other organic matter less than 100 mg per m of finned tube surface area. Specialised equipment includes a purpose-designed vapour degreasing plant and an analytical balance for in-house quality control. Continuous monitoring of contamination levels is undertaken with independent certification by Vecom Laboratories in Holland. Oxygen cooler bundle in manufacture.
VACUUM, EVAPORATION AND INDUSTRIAL REFRIGERATION TECHNOLOGIES EVAPORATION GEA has extensive know-how in evaporation/thermal separation technology including: Falling film evaporators Counter flow trickle evaporators Climbing film evaporators Flash evaporators Forced circulation evaporators Spiral tube evaporators for the chemical and pharmaceutical industries. The best adapted evaporator will provide users with: maximum reliability and working life minimum maintenance optimised efficiency. These evaporators are equipped with highly efficient separation systems: to obtain cleaner vapour to enable the use of less expensive construction materials to recover condensate which may be re-used in the rinsing section of the surface treatment plant. The flow-scheme is optimised within the limits imposed by the main set conditions, i.e: the quality of the product to be processed the prevention of product deterioration the protection of the environment the reduction of operating and maintenance costs.
VACUUM TECHNOLOGY A steam jet ejector has no moving parts and is used to pump, mix, heat, cool or produce vacuum. Pressurised liquid, steam or air is used as the motive or driving fluid. The motive fluid is passed through a set of nozzles, where its pressure energy is converted into a high-velocity jet.
Package refrigeration unit Plant using column cooling system CRYSTALLISATION All types of crystallisers, working to the principles of: evaporation cooling or equilibrium displacement continuous/batch crystallisation.
Designed for: purification of product or process streams industrial processing of organic or inorganic products (organic acids, fertilisers, etc.) upgrading of by-products from liquid waste in environment protection programmes liquid treatment stripping, ozonation, liquid-liquid extraction, centrifugation, filtration, decanting, spray-drying vapour/gas treatment: extractive distillation, scrubbing, cleaning, absorption, incineration solids treatment i.e. calcination, incineration, thin-film drying, flash drying, fluid-bed drying, flaking, prilling, bagging, etc.
REFRIGERATION The constant progress being made in industrial processing technology demands a greater use of refrigeration cycles for: control or removal of the heat produced by chemical reactions or physical processes condensation and liquefaction for separation or recovery crystallisation for purification or recovery preservation of product characteristics and prevention of side-effects security measures to prevent runaway reactions, pressure rises, etc. containment of heat losses from an ambient and maintaining thermal equilibrium of a system, or of phase equilibrium.
DIRECT AIR-COOLED CONDENSERS WORLD LEADER IN DIRECT AIR-COOLED STEAM CONDENSERS In 1979 GEA became involved in feasibility studies for Eskom in respect of new generation large scale power stations using dry cooling systems. This research and development culminated in the award of a turnkey contract in 1982 for the design, manufacture, supply, delivery, erection and commissioning of six air-cooled steam condensers for Eskom's 6 x 665 MWe Matimba Power Station. This constitutes the largest direct air-cooled steam condenser installation and, therefore, the largest direct air-cooled power station in the world. In 1984, Eskom also placed with GEA the order for air- cooled condensers for the 6 x 660 MWe Majuba Power Station.
Two features distinguish the GEA air-cooled condenser: highly efficient and durable finned tubes, and a single-pressure two-stage condensing process. The GEA air-cooled condenser is comprised of finned tube bundles grouped together into modules and mounted in an A-frame configuration on a concrete or steel support structure. Vertical and horizontal configurations are also available. GEA employs a two-stage, single-pressure condensing process to achieve efficient and reliable condensation. In this process, the steam is first ducted from the steam turbine to the air-cooled condenser, where it enters in parallel/concurrent flow from the top. The steam is only partly condensed in the parallel flow modules and the remaining steam is ducted to the lower headers of the counterflow finned tube bundles (dephlegmator). The steam enters from the bottom and rises in the finned tubes to a point where condensation is completed. Non-condensables are drawn off above this point by vacuum equipment. The condensate drains to a condensate tank and is then piped back to the feedwater system to complete the cycle. Matimba Power Station, Ellisras, South Africa - the largest direct air-cooled power station in the world. Winner in 1988 of the South African Institute of Mechanical Engineers, Project and Systems Award.
HOW DOES THE PAC SYSTEM TM WORK? Exhaust steam from the steam turbine is separated into two streams. One stream flows into a water cooled surface condenser while the other is directed to an air-cooled condenser. Condensate from the surface condenser and the air-cooled condenser can be collected in a common hotwell. Water consumption is controlled by the distribution of the heat load between the two condensers. The PAC System TM should not be confused with a "hybrid" cooling tower, which is used primarily to reduce visible plume from a wet cooling tower. A "hybrid" cooling tower has practical limits to the amount of heat that can be rejected in the dry section, since the latter is sized for plume abatement only. With the PAC System TM there is complete flexibility in the amount of heat rejected in the dry section. The dry section of the PAC System TM employs direct condensation in contrast to most "hybrid" systems, which are indirect condensing systems, i.e. water is cooled through both the wet and dry sections and is then pumped through a common condenser. As a result, the dry section of the PAC System TM can efficiently reject a substantial amount of heat even on hot days, thereby reducing peak water usage. During cooler periods, the amount of heat rejected in the dry section can be increased up to 100% if so designed, thus further reducing the plant's water consumption. An additional benefit of the PAC System TM is the reduction of plume. Plume can be reduced or eliminated entirely when danger of icing exists, simply by shutting off the wet section.
Parallel condensing system (PAC).
EVAPORATIVE COOLING SYSTEMS (CT + BAC) Cooling systems utilising water evaporation are usually the most cost-effective heat rejection systems. In a cooling tower hot water from a plant is brought into contact with ambient air and heat is transferred from the water to the air by evaporation (mass transfer) and convection (heat transfer). The cooled water is then returned to the plant. Generally, evaporative cooling systems can achieve lower re-cooled water temperatures and a lower condenser vacuum than dry cooling systems. In cooling tower terminology, range is the difference between the water inlet temperature and the re-cooled water outlet temperature. The difference between the re-cooled water temperature and the ambient air wet bulb temperature is known as the approach. Generally a cooling tower becomes very large if the approach is reduced below 4 C. Evaporation rates are approximately 1.5 to 2 m/hr per MW of heat rejection or 1 to 2% of flow rate. In order to keep the dissolved solids in the circulating water at an acceptable level, a fraction of the circulating water is discarded, i.e. the blowdown stream. A stream of fresh makeup water is required to replace the water lost by evaporation and blowdown.
Main activities in evaporative cooling field: Design and construction of new turnkey evaporative cooling systems (custom built units), including pipework, valves, pumps, intermediate heat exchangers, variable speed drives, sound attenuators, etc. Cooling tower inspections Cooling tower performance testing and system evaluation Improvement/modification of existing systems Cooling tower repacking and refurbishment Maintenance.
Mechanical draft cooling tower at Eskom's Majuba Power Station.
Mechanical draft cooling tower at Belle Vue Power Station - Mauritius.
MECHANICAL DRAFT COOLING TOWERS (MDCT) Mechanical draft cooling towers make use of a fan to generate the air-flow through the tower. Depending on the cooling load, multiple cells, each with its own fan, can be employed. Fan diameters of up to 30 ft are commonly used. The relative flow direction of the water and the air streams can be arranged in either cross or counterflow. Generally, counterflow cooling towers are preferred nowadays, due to their higher thermal efficiency. For a given duty, the initial cost of mechanical draft cooling towers is lower than that of natural draft cooling towers.
Mechanical draft cooling tower
NATURAL DRAFT COOLING TOWERS (NDCT) In a natural draft cooling tower, the natural buoyancy of the hot air moves the air upward through the tower, drawing in fresh cool air through the air inlet at ground level. No fan is required. Due to the layout of this type of cooling tower the possibility of hot air recirculation (and the resultant performance drop) is negligible. The tower shell is usually constructed in reinforced concrete, and can be as high as 200 m. Due to the high cost of the large concrete structures, natural draft cooling towers are usually only employed for large heat duties.
Natural draft cooling tower
In South African mines bulk air coolers (BAC's) are often employed to provide large quantities of cold air for mine ventilation. Basically, a bulk air cooler is an inverted mechanical draft cooling tower in which cold water from a refrigeration unit is used to cool the incoming air and to provide a stream of cold air into the mine. Bulk air coolers are constructed in crossflow and counterflow layouts. Crossflow units are usually used underground where the available height is restricted. Closed circuit evaporative coolers and condensers employ heat exchanger bundles inside the cooling tower. This allows the cooling of any liquid by means of evaporative cooling. It is also possible to achieve this by using an intermediate heat exchanger, such as a plate heat exchanger or shell and tube heat exchanger in conjunction with an evaporative cooling tower. GEA is continuously improving the quality and the cost-effectiveness of its evaporative cooling products. With the dramatic improvement in the quality of plastic materials, we have in the recent past replaced nearly all our cooling tower components with plastic components, which have proved to be superior to those used previously. All these improvements have enabled us to supply our clients with cooling towers, which will not only require less maintenance, but which will also have a longer operational life.
GEA Aircooled Systems recently developed a new low-cost pre-cast concrete panel type cooling tower (PTCT) as part of its drive to offer our clients increased quality at reduced prices.
OTHER EVAPORATIVE COOLING SYSTEMS Features of PTCT: 2.1 m wide pre-stressed, pre-cast concrete panels Pre-cast concrete roof slab Pre-cast concrete or GRP fan stacks Cable tensioning after assembly results in a very rigid structure compared to other pre-cast concrete cooling towers. Advantages of PTCT: Low cost Rapid construction No civil work on site except for floor slab and ground works, for fast-track projects Can be disassembled and relocated High grade concrete (60 MPa) Very rigid structure compared to other pre-cast concrete cooling towers.